In 2008 the SGL Carbon Company, Wiesbaden, and Paderborn-based Benteler Automotive launched a joint venture to develop, produce and market components based on carbon fiber reinforced composites (CFRP) for the automotive industry with the approval of the relevant antitrust authorities. Each company has a 50 percent stake in the joint venture Benteler SGL GmbH & Co. KG, based in Paderborn.

The objective for the first collaborative phase is to develop structural and other components using CFRPs – such as B-columns, crash boxes, bumpers, and axles. The second, medium-term objective is to start up serial production of these products for the automotive industry. Significant growth in the market segment for CFRP components is forecast by industry experts.

Considerable weight reductions from CFRPs

Light-weight vehicle design is one of the major discussion topics in the automotive industry. The main focus was on reducing fuel consumption and CO^₂ emissions. All vehicle manufacturers are increasingly associating light-weight design with the use of CFRPs. Significant vehicle weight reductions can be achieved with these materials. The weight of carbon fiber reinforced composites is only around 50 percent of aluminum and 20 percent of steel. The material also possesses unique advantages such as excellent crash characteristics, low fatigue behavior and high corrosion resistance. It is also a factor in dampening vibration and benefits from very low thermal expansion. 

Focus on collaboration between SGL Group and Benteler: Cost reduction

Carbon fiber reinforced composites are manufactured by impregnating carbon fibers with liquid resin, after which they are subjected to heat and pressure to convert them into solid components. The SGL Group holds the full range of carbon fiber semi-finished products required for manufacturing CFRP components within its Business Line Composite Materials. These include carbon fiber fabrics, woven products, braidings (from SGL Kümpers GmbH, established in January 2007) and prepregs, i.e. textiles pre-impregnated with resin. However, the high manufacturing costs of CFRP components have so far only permitted high-performance applications in motor racing and exclusive vehicle construction. Because of the high cost of components, CFRPs are today rarely used for vehicles manufactured serial production. Large-scale automated production of these components would reduce manufacturing costs to a level which would make serial production possible.

In February 2009 Benteler-SGL acquired the Fischer Composite Technology GmbH in Ried, Austria, in order to enhance the process and product portfolio and to create a direct market access to new customer groups for composite components.

The combined know-how of both companies offers excellent potential for growth in the future market of automotive lightweight construction.